Structural panel system

ABSTRACT

A structural panel has unitary load transfer members with their length subdivided into shorter, stiffer load-transfer portions separated by stabilization zones. These members are in mutually inclined back-to-back relation, and can be flexible or substantially rigid, with plain or profiled section, being of board, metal or plastic to provide an integrated high load-bearing capacity. A concertina assembly of such lightweight struts can replace a number of orthodox studs. The strut members are fastened together, and mutually secured, in back-to-back pairs or stabilized by the adjoining frame and/or the panel face members. Reinforcement by tension elements, strapping and foamed plastic may be used.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation in Part of application Ser. No.10/761,307 filed Jan. 22 2004.

BACKGROUND OF THE INVENTION

This invention is directed to a structural panel system, and inparticular to a frame structure incorporating slender unitaryload-transfer members extending between the frame end members in loadtransfer relation, the load-transfer members having one or morestabilization zones located along their length in contacting relationwith a lateral stabilizer, such that the load transfer members arestiffened against lateral deformation under load.

2. In the past, structural panels, such as walls and partitions havelargely consisted of a sill and lintel end member, with a number ofregularly spaced upright stud members in supporting, load bearingrelation therebetween. The faces of the partition are then enclosed withsheeting, such as drywall, wallboard etc, which is nailed to the studsand frame members. The studs, which may be referred to as 2× (or “twoby”) can range in size from 2″ by 3″, 2 by 4 (commonly called “two byfour”), 2″ by 6″, even 2″ by 8″ being used.

The centre-distance spacing of the stud members is usually sixteeninches, so that standard four foot wide sheeting fits edge to edge ofthe frame side members.

Studs at two-foot centres also may be used in the same fashion, to thesame effect.

Generally the members consist of wooden two-by-fours, although in someinstances sheet-metal stud members have replaced the wood ‘2 by 4’ studmembers.

These traditional structures require large quantities of wood, are bulkyand heavy to transport, and expensive.

BRIEF SUMMARY OF THE INVENTION

The present invention provides a structural panel system, suitable foruse as a wall or other framed structure incorporating unitaryload-transfer members arranged in laterally stabilized relation within acontaining framework.

The subject strut members are of slender section modulus, such thatunder typical longitudinal thrust loads, being flexible, they wouldindividually buckle.

By providing a stabilization zone located midway along its length, withstabilization means contacting the stabilization zone in lateralconstraining relation with the load transfer (strut) member, thetendency of the load transfer members to deform under load issubstantially reduced; i.e. its buckling load capacity can beeffectively doubled. Use of a greater number of stabilization zones,such as two or three creates three or four strut portions, with acorresponding tripling or quadrupling of the stiffness of the respectiveload transfer strut portions, depending on the number of stabilizationzones that are provided.

In one embodiment, by arranging load transfer strut members in pairs,having their outer ends joined, and by laterally constraining the strutpairs at their centre-points, the load-bearing capacity of an integratedseries of such pairs may be effectively doubled, and made adequate forthe strength requirements of a partition or non-load-bearing wall, theload-bearing ‘column’ length of each strut having been effectively atleast halved.

The lateral constraint for the pairs of strut members may be supplied byadjoining strut pairs in mutual abutting relation, and by the frame sidemembers or by one or more standard frame stud members that may beretained for that purpose, as frame side members.

As an example, an eight foot long section of partition wall,constituting a structural panel unit, normally having seven two-by-four(2×4—actually 1¾ inch by 3¾ inch) wood stud members, can have four ofthe eight-foot 2×4 studs replaced by two assemblies, each consisting offour pairs of the subject inclined strut members. A wooden stud memberseparates the two strut assemblies as part of the framing, and helps tosecure them in place.

Typically, the upper and lower ends of a pair of strut members may besecured to each other to form a juncture, by gluing, sewing or stapling,and glued to the adjoining end (sill and lintel) members of thecontaining frame; being glued/stapled at their centres to the adjoiningpair of strut members, and glued, nailed or stapled to the abutting 2×4frame side members.

Alternatively, by nailing/stapling and/or gluing the centre portions ofthe two outer strut members of a strut assembly to the adjoining framestuds, so as to laterally secure the strut assembly in its ‘working’position, the individual struts can be stabilized in that position bygluing the juncture portions at their edges to the adjoining facesheeting which encloses the structure.

This would consist of spot-gluing edge portions of the strut, at theirjoined ends and at their intermediate juncture portions, by coating theedges of these parts with glue just prior to applying the face sheeting,on enclosing the face of the structure.

Other means of stabilizing the strut members of an assembly includelateral grooving of the sill and lintel members to receive the strutends, or the use of spacer strips located between adjacent struts, andsecured to the sill or lintel.

In addition to containing the bowing of the combined strut members byway of the frame side members, the use of a transverse tie member suchas metal or wood strapping or a nylon or other high strength filament orwire, extending between the frame side members is contemplated, whereinthe tie member would be secured to the stabilization zones of thestruts. Such tie members thus serve to stabilize the strut memberportions at their junctures.

Strapping tie members may be located beside the struts, to secure thestruts at their juncture lateral edges, while the wire, cable orfilament is preferably passed through the centre of each juncture, andsecured to each strut, to maintain their mutual spacing, as well as totie the frame side members against outward bowing, in the plane of thestructure.

The combined strut members may use a variety of materials, oneembodiment utilizing a flexible wood-based pressed sheetboard ofpredetermined thickness and longitudinal stiffness, such as “Masonite”(T.M.). Other material embodiments such as metal or plastic strutmembers may be readily adopted, in which profiled sections withstiffening side flanges are used. The materials include aluminum sheet.

While one embodiment consists of strut members having two inclinedload-bearing portions of its length, it will be understood thatmultiples of this arrangement may be adopted, with struts having four,six or even possibly eight inclined, load bearing portions along itslength, to provide an eightfold increase in stiffness and load-transfercapability.

With adequate lateral stabilization, the adoption of shorter loadbearing strut portions has the effect of correspondingly increasing theEuler (buckling) stiffness of the struts. The promotion of lateral strutstability may include the use of plastic foam injected in lateralsupporting relation into the interstices of the struts, to bear againstthe strut faces, wherein use is made of the high compression strength ofthese plastic foams, even those of comparatively low density. Fire andother safety considerations have to be observed, usingself-extinguishing foams. Foams also serve to suppress noisetransmission.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Certain embodiments of the invention are described by way ofillustration, without limitation thereto other than as set forth in theaccompanying claims, reference being made to the accompanying drawings,wherein:

FIG. 1 shows a side elevation of a typical section of Prior Artpartition wall framework in a partially enclosed condition;

FIG. 2 is a side elevation of a partially completed partitionconstruction in accordance with the present invention;

FIG. 3 is a front perspective view of the FIG. 2 embodiment;

FIG. 4 is a perspective view similar to FIG. 3 of a panel structureincorporating profiled section strut members and a tensioned lateraltie;

FIG. 5 is an enlargement of a portion of FIG. 4;

FIG. 6 is a perspective view of an undeformed strut member of the FIG. 4embodiment;

FIG. 7 is a side elevation of a partially completed wall section showingthe nailing installation of a strut assembly, and an electrical wiringinstallation;

FIG. 8 is an elevation of an enclosed partition section; before tapingand plastering;

FIG. 9 shows a further subject strut embodiment in a wall construction,and

FIG. 10 shows a panel embodiment as a portion of a floor installation.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, a typical Prior Art framework 10 of a partition hasa sill member 12, a lintel member 14, and stud members 16, all of whichmembers are usually of wood, in nominal ‘two-by-four’ (2″×4″) section.Frame sections may range from ‘2 by 2’ to ‘2 by 8’, or even deeper (iemembers of two inch nominal thickness by up to eight inch or greaterwidth).

The partition is shown having the reverse face enclosed, such as bydrywall.

In the FIGS. 2 and 3 embodiment of the present invention, aprefabricated “concertina” assembly 20 consisting of pairs of strutmembers 22, having their upper and lower outer ends 24 secured together,as by gluing and/or stitching and/or stapling and entered into slots 26in the top and bottom (sill and lintel) members 12, 14 of a partiallyenclosed structure.

The assembly 20 has the mid point stabilization zone 28 of the adjoiningouter faces of the members 22 similarly secured in back-to-back relationas part of the fabrication process. In this embodiment the flexiblestrut members 22 are originally planar.

In one embodiment the struts 22 were flexible strips of composite panelboard, a thickness of ⅛ inch being used, the panel board being plywood.

Other suitable forms of flexible board may include wood, particle board,OSB (wafer board), LDF, MDF or HDF (low, medium or high densityfiberboard) panels, hardboard, and combinations of laminated panels andfiberglass.

A “concertina” consisting of eight strips of board, is made up as fourpairs of flexible strip, each pair having their upper and lower outerends 24 secured together, and adjoining pairs having their mid-sectionouter surfaces 28 secured together in back-to-back mutually attachedrelation.

The composite “concertina” of struts is cut to length so as to fit,under axial compression, into the slots 26, so as to fill the apertureof the frame members 12, 14, 16. It will be understood that slots 26 maybe eliminated, and gluing and other spacer means may be substituted, tosecure the struts in place.

In FIGS. 4, 5 and 6, the struts 32 are of metal or moulded or extrudedplastic, having side flanges 34, with planar end portions 36 and planarintermediate centre portions 38, which may be pre-perforated toaccommodate a tensioned member 40.

Side reliefs may accommodate straps.

A tensioned monofilament member or wire 40 is shown, the ends of whichare secured to the frame side members 16. The member 40 serves to holdouter frame members 16 against outward bowing under the effect of thelateral reaction forces produced by the struts 32, while also retainingthe struts 32 in aligned relation with the frame members 16, prior totheir being enclosed by the enclosing wall board or paneling.

The struts 32 are shown in a substantially planar condition. However, itwill be understood that the ultimate angles of inclination of the endportions 36 and centre portion 38 may be pre-set to substantially thedesired angles.

In FIG. 7, the normally concealed, behind-the-wall portions of a wallswitch 42, electrical outlets 44 and wiring 46 are shown; also nails 48that secure the strut concertina assembly 20 to the frame side members16.

FIG. 8 shows the manner of closure of a portion of an assembled wallstructure, by way of paneling or wall-board, which is nailed, stapled orglued to the frame members. It is at this stage that plastic foam, suchas engineering foam with high compression strength may be applied, tolimit or prevent buckling deflection of the struts. If used, the foamhas a significant noise suppression effect.

The wall joints are then taped and plastered.

In FIG. 9, a wall assembly having a doorway and window opening alsoshows the use of nails to secure the flexible strut concertina assembly20 to the frame side members 16. The strut assembly 20 shows the use ofcommercial staples 50 to reinforce the mid-section glued attachment ofadjoining pairs of struts in joined relation. Staples 50 may also beused in attaching the strut assembly 20 to the adjoining frame sidemembers 16. The final step of installing a strut assembly may consist ofgluing parts of the strut assembly to the enclosing wall board. This isdone as a substitute for, or to reinforce the use of the slots 26. Theglue is applied to edge portions of the strut members 22, 32, to securethem to the adjoining drywall, panel board or other member by which thepartition structure is enclosed. This glue application is preferablyfocused at or adjacent the ends 24, 36 of the struts, and also at theouter edge surfaces of the stabilization zones 28.

In FIG. 10, a structure 60 in accordance with the present invention isshown mounted upon floor joists 62 as a flooring panel. The panelstructure 60 has substantially rigid frame edge members 66, 68, withpanel lower face member 64 and upper face member 70. The load transfermembers 72 are illustrated as being a sandwiched corrugate, wherein theedge presentation of the corrugate provides great crushing strength tothe panel structure 60. It is contemplated that the face members 64, 66contact in bonded relation with frame members 66, 68 and the top andbottom edge surfaces of the members 72.

In the illustrated embodiments of FIGS. 2, 3 and 4, the angle ofinclination of the bowed strut members 22, 32 is approximately 20degrees, which means that the potential vertical load capacity of eachstrut member is approximately 94% of its developed longitudinalcompressive strength.

Correspondingly, the lateral component of thrust load, which iscontained by the frame side members 16 together with the tensionedmember 40 (or side strapping when used), amounts in this instance toabout a mere 6% of the strut thrust load.

The arrangement of the strut members 22, 32 in inclined, mutuallysupporting, back-to-back relation, with mid-point stabilization givestwo thrust-bearing strut portions, which sensibly halves the Euler(buckling) strut length of each strut portion, with a correspondingapproximate doubling in load-bearing capacity of the total strut.

For strut members with quarter point stabilization, having four inclinedload-bearing segments, the stiffness or thrust load transfer capacity issubstantially quadrupled.

The foregoing embodiments of the present invention disclose its use inpanels of limited size. However, it will be understood that other, lesslimited embodiments are contemplated, within the scope of the presentclaims.

1. A structural panel unit having an enclosing frame with a pair ofmutually opposed frame end members and a pair of mutually opposed frameside members; a plurality of unitary load-transfer members extendingbetween said end members in load transfer relation therebetween, eachsaid load-transfer member having at least one stabilization zone locatedalong its length intermediate said frame end members; stabilizationmeans contacting said stabilization zones in lateral constrainingrelation with said load transfer members, whereby the tendency of saidload transfer members to deform under load is substantially reduced. 2.The structural panel unit as set forth in claim 1, wherein some of saidload transfer members have another said load transfer member in adjoinedmutual stabilizing contact relation at said at least one stabilizationzone.
 3. The structural panel unit as set forth in claim 1, wherein atleast one said load transfer member has an adjacent said frame sidemember in stabilizing contact relation at said at least onestabilization zone.
 4. The structural panel unit as set forth in claim1, wherein said enclosing frame is substantially filled with pairs ofsaid load transfer members, with some of said pairs of members arrangedin back-to-back mutually stabilizing relation; and with said frame sidemembers contacting some of said load transfer members in transversestabilizing relation therewith.
 5. The structural panel unit as setforth in claim 1, said load transfer members having a plurality of saidstabilization zones in mutually spaced relation along their length, toprovide a plurality of shortened strut portions connected in end-to-endrelation, each said shortened portion having substantially greaterresistance to buckling than a laterally non-stabilized said loadtransfer member.
 6. The structural panel unit as set forth in claim 2,said load transfer members having a plurality of said stabilizationzones in mutually spaced relation along their length, to provide aplurality of shortened strut portions connected in end-to-end relation,each said shortened portion having substantially greater resistance tobuckling than a laterally non-stabilized said load transfer member. 7.The structural panel unit as set forth in claim 3, said load transfermembers having a plurality of said stabilization zones in mutuallyspaced relation along their length, to provide a plurality of shortenedstrut portions connected in end-to-end relation, each said shortenedportion having substantially greater resistance to buckling than alaterally non-stabilized said load transfer member.
 8. The structuralpanel unit as set forth in claim 4, said load transfer members having aplurality of said stabilization zones in mutually spaced relation alongtheir length, to provide a plurality of shortened strut portionsconnected in end-to-end relation, each said shortened portion havingsubstantially greater resistance to buckling than a laterallynon-stabilized said load transfer member.
 9. The structural panel unitas set forth in claim 1, portions of the length of said load transfermembers being of non-planar cross-section, having enhanced resistance tobuckling deformation under load transfer conditions.
 10. The structuralpanel unit as set forth in claim 1, portions of the length of said loadtransfer members being flanged, to provide enhanced resistance tobuckling deformation under load transfer conditions.
 11. The structuralpanel unit as set forth in claim 2, portions of the length of said loadtransfer members being of non-planar cross-section, having enhancedresistance to buckling deformation under load transfer conditions. 12.The structural panel unit as set forth in claim 11, portions of thelength of said load transfer members being flanged, to provide enhancedresistance to buckling deformation under load transfer conditions. 13.The structural panel unit as set forth in claim 3, portions of thelength of said load transfer members being of non-planar cross-section,having enhanced resistance to buckling deformation under load transferconditions.
 14. The structural panel unit as set forth in claim 13,portions of the length of said load transfer members being flanged, toprovide enhanced resistance to buckling deformation under load transferconditions.
 15. The structural panel unit as set forth in claim 4,portions of the length of said load transfer members being of non-planarcross-section, having enhanced resistance to buckling deformation underload transfer conditions.
 16. The structural panel unit as set forth inclaim 15, portions of the length of said load transfer members beingflanged, to provide enhanced resistance to buckling deformation underload transfer conditions.